Simultaneous flocking



Sept. 12, 1944. G. s. HlERS 2,358,227

SIMULTANEOUS FLOCKING Filed March 15, 1941 2 Sheets-Sheet 1 FIG. I

FlG. H.

INVENTOR GLEN SEFTON HIEQS RNEY Sept. 12, 1944. G. s.- HIERS 2,353,227

SIMULTANEOUS FLOCKING Filed Ma .rch 15, 1941 2 Sheets-Sheet 2 5a 4 i 54e1 lNVENTOR GLEN SEF'TON HIEQS BY x lzv Patented Sept. 12, 1944 orricaSIMULTANEOUS FLOORING Glen Sefton fliers, Bah-011M111, Pa, aslignor toCollins & Altman Oorporation, Philadelphia, Pa., a corporation ofDelaware Application l l'al'ch 15, 1941, Serial No. 383,614

l'lclaima .Thls invention relates to an apparatus for and method ofproducing flocked textile fabrics by electrostatic methods.

According to my invention, two or more base fabrics may besimultaneously flocked between opposing electrodes of an electrostaticfield producing apparatus with the result that production is speeded upand economies are eifected in the cost of manufacture,

The electrostatic field may be created between the opposing electrodesby the impression of a high potential thereupon, and may be of eitherpulsating, alternating or direct current of alternating polarity. I

The fibers used'may be either of pile forming or of shorter lengths andmay be fibers of poor electrostatic susceptibility, such as wool,mohair, cellulose acetate, casein wool, nylon and silk, or of naturallygood electrostatic susceptibility, such as cotton and viscose. Fibersof'poor susceptibility may, if desired, be treated as described in mycopending application Serial No. 366,713 to improve their electrostaticresponse characteristic, but such treatment is not essential to thebroadest concept of the present invention.

The base fabrics, prior to being positioned or passed between theelectrodes, are coated with an adhesive coating which may be of solventrubber cement or of resin, latex, pyroxylin, or other composition. Theadhesive may be applied as by a spreading doctor blade, pressure rollsor other convenient means.

The opposing electrodes may be of any suitable shape and may bepositioned horizontally or vertically or otherwise. If positionedhorizontally, the flock fibers may be injected into the field betweenthe fabrics as .by aspray gun of conventional type, whereas in the caseof vertically positioned electrodes the flock fibers may be sifted anddropped into the field between the fabrics as from ahopper.

As hereinafter described, I have discovered that flock fibers may beintroduced between the adhesively coated surfaces of two or more basefabrics positioned facing each other in a high potential electrostaticfield to accomplish simultaneous flocking of the coated fabrics withoutany adhesive discernible'appearing on the tips of the deposited fibers,despite the fact that the fibers appear to move back and forth withinthe field between the coated surfaces before finally adhering to one ofthem.

It is an object of this invention to provide apparatus for and a methodof simultaneously flocking a plurality of base fabrics in a highpotential electrostatic field.

It is another object of this invention to simultaneously flock aplurality of base fabrics in a high potential electrostatic field ofregularly alternating polarity.

, Another object is to simultaneously flock a plu rality of base fabricsin a pulsating high potential electrostatic fleld of regularlyaltemating' 1o po arity.

Another object is to provide apparatus for and a method ofsimultaneously flocking with pile forming fibers a plurality of basefabrics in a high potential electrostatic field.

Another object is to simultaneously project untreated flock fibers ofpoor electrostatic susceptibility upon a pluralityof adhesively coatedbase fabrics positioned between opposing electrodes.

An additional object is'to simultaneously proiect flock fibers of goodelectrostatic susceptibility upon a plurality of adhesively coated basefabrics positioned between opposing electrodes. 7

These and other objects of invention will be manifest from thespecification and claims and 5 from the following description of thepreferred embodiment illustrated in the drawings, wherein: Figure I is adiagrammatic side elevational view of apparatus for simultaneouslyflocking two base fabrics in an electrostatic field established betweena pair of vertically positioned opposing electrodes, and includes aschematic drawing of an electric circuit suitable for furnishingalternating current, energy to the electrodes.

In Figure 11 is shown a schematic'drawing of an electric circuitsuitable for furnishing pulsating energy of alternating polarity to theelectrodes.- v

Figure III is a diagrammatic side elevational view of apparatusembodying my invention in which a pair of fabrics is passed laterallythrough an electrostatic field established between horizontallypositioned electrodes.

Figure IV is a diagrammatic side elevational view showing four basefabrics passing laterally through an electrostatic field establishedbetween horizontally positioned electrodes.

Referring to the drawings, in Figure I there is illustrated a pair ofbase fabrics l0 and H of cotton or other suitable material fed fromsupply rolls l2 and I3 and passed over guide rolls ll, l5, l6 and I! toan electrostatic field i8 established between opposing electrodes illapplied to the side of each base fabric It and II which faces the otherat spaced separation the hopper into the field between the coatedsurfaces of the base fabrics, and receptacle 23 may be placed beneaththe field'for collecting'the undeposited flock.

Electrical energy for the establishment of a high potentialelectrostatic field of alternating polarity and, controlled freq encymay be furnished by apparatus and circuit of the type shownschematically in FigureI, wherein a low voltage direct current motor 29,driven from any convenient source of low voltage direct current power P,and whose speed is controlled by rheostat 30, is mechanically coupled toand drives a low voltage alternating current generator 3|. The frequencyof the low voltage alternating current produced by generator3l is afunction of the number of poles of the generator and the speed to whichit is driven by motor 23, and the frequency desired for theelectrostatic field is accordingly available through control of thespeed of rotation. To convert the low voltage output of the generator tohigh voltage, the machine may be connected to the-low side of a steptheswitch is thrown twelve times per second in timed relation with the linealternations.

Other known and conventional means of providing energy for establishingalternating, direct current of alternating polarity, or pulsating highpotential fields may, of course, be used.

After passing through "the field, the flocked fabrics HI and II (FigureI) may be passed over guide rolls 39 and 40 to drying chambers 4| and42, where the adhesive is set.

In Figure III there is illustrated a pair of base fabrics 43 and 44 fedfrom supply rolls 45 and 45 and passed over guide rolls 4], 48, 49, 50,5| and 52 to the electrostatic field 53, established betweenhorizontally positioned electrodes 54 and 55. An adhesive 56 is appliedtoeach fabric by conventional means, as by doctor blades 51 and 58,before the fabrics are passed into the field with their coated surfacesfacing each other at spaced separation. The flock 59 may be injectedinto the field between the coated surup transformer 32 through asuitable voltage control rheostat 33. The high side of the transformermay be connectedto the electrodes l9 and 20, which may be of aluminum orother suitable material. One of the electrodes is preferably grounded. Ihave found voltagesof from to 100 kv. and'frequencies of from 2 lowvoltage alternating current line supply S is connected through voltagecontrol rheostat 34 and reversing switch to step-up transformer 36 andthence to mechanical rectifier 31, which may be driven by synchronousmotor 33 at a speed in synchronism with the line current. When thereversing switch is not operated, the output of the mechanical rectifier31 is a pulsating high voltage current which may be connected directlyto the electrodes l8 and 20,, one of which is preferably grounded.Voltages of the order of from 30 to 100 kv. are preferred.

By reversing the switch 35 *at regular or irregular intervals, themechanical rectifier 31 is caused to deliver a pulsating: high voltageof correspondingly regular or irregular alternating whereby theswitching occurs only when the line voltage is passing through zero. Forexample, where a 60 cycle line frequency is to be confaces, asby spraygun of known type. Upon leaving the field, the flocked fabrics 43 and 44may be passed over the guide rolls GI and 62 to drying chamber 63 andthence over guide rolls 64, 65 66 and B1 to the roll up of the finishedfabric. The flocked fabrics maybe beaten or brushed as at 68 or B9 toremove any excess flock. 1

In Figure IV there are illustrated four base fabrics 10, H 12 and 13,passing over guide rolls 14, 15, "I5, 11, 18,19, 80, BI and 82 toelectrostatic field 83 established between horizontal electrodes 84 and85 and coated with adhesive 86 by conventional doctor blades 81, 88, 89and 90. Flock fibers SI and '92 may be injected into the field betweenthe coated fabrics by spray guns 93 and 94 of known type. Upon'leavingthe field the flocked fabrics may be passed over guide'rolls 95, 96, 91and 98 to drying chamber 99 and thence over guide rolls l llll, I III,I02, and ")3 to the roll up of the finished fabric. Priorto the roll up,any excess fiock may be removed as by beating, brushing, suction orother convenient means. The arrangement shown in Figure IV is merelyillustrative of one manner of flocking more than two base fabricssimultaneously. Other arrangements may, of course, be used, includingother verted into a 5 cycle electrostatic field frequency,

conventional means of applying the adhesive and of injecting the flockfibers into the field.

When the flock fibers are introduced into the high potentialelectrostatic field between the adhesively coated surfaces of the spacedapart base fabrics positioned therein, simultaneous flocking of thefabrics occurs. Excellent results are obtained in an electrostatic fieldof regularly alternating polarity of from 2 to 20'cycles per secondusing either untreated fibers of poor electrostatic susceptibility, sucha wool, mohair or cellulose acetate, or fibers of good electrostaticsusceptibility. Excellent results are also obtained with either type offiber in a pulsating field of regularly alternating polarity thepreferred frequency of which is on the same order, namely, from 2 to 20cycles per second. Good results are also obtained in a direct'currentfield of alternating polarity with fibers of good electrostaticsusceptibility, either naturally or by treatment.

No effort will be made herein to present a theoretical explanation ofthe phenomena which occur when the flock fibers are introduced into thehigh potential electrostatic field between the coated surfaces. In thealternating field, fibers appear to rain back and forth between thefabrics in synchronism with the alterations of polarity,

. vented from lodging in the adhesive by other fibers already depositedtherein. That is to say, it is believed that fibers which reach theadhesive are lodged therein and are not thereafter removed by theensuing action of the electrostatic forces of the field.

In the case of the pulsating field; good results are obtained, ashereinbefore indicated, provided the fibers are of good electrostaticsusceptibility. In such a field, fibers also appear to rain back andforth between the coated fabrics, and examination of the face of theflocked fabrics reveals no adhesive upon the tips of the fibers. It isbelieved that the fibers which move back and forth in the unidirectionalfield are those whose lodgment in the adhesive is prevented bypreviously deposited fibers, and that these fibers become charged withthe same polarity as the fabric and are consequently repelled therefrom.

Whatever the explanation, I have found that simultaneous flocking ofspaced apart adhesively coated surfaces may be accomplished withentirely satisfactory results. 7

Having described my invention but wishing to be limited only by theclaims, I claim:

1. In the manufacture of flocked textile fabrics, the method ofsimultaneously flocking a plurality of adhesively coated base fabrics,including the steps of establishing a pulsating high alternatingpotential electrostatic field between opposing electrodes, positioning aplurality of adhesively coated base fabrics between the opposingelectrodes with the coated sides of each pair of base fabrics facingeach other and introducing fiock fibers into the field, whereby the basefabrics are simultaneously flocked.

2. In the manufacture of flocked textile fabrics, the method ofsimultaneously flocking a plurality of adhesively coated base fabrics,including the steps of establishing a. pulsating high alternatingpotential electrostatic field between opposing electrodes, positioning aplurality of adhesively coated base fabrics between the opposingelectrodes and introducing flock fibers into the field adjacent thecoated surfaces, whereby the base fabrics are simultaneously flocked.

3. In the manufacture of flocked textile fabrics, the method ofsimultaneously flocking a plurality of adhesively coated base fabrics,including the steps of establishing a pulsating high alternatingpotential electrostatic field between opposing electrodes, positioning aplurality of adhesively coated base fabrics between the electrodes withthe coated surface of each fabric facing the coated surface of anotherat spaced separation and introducing flock fibers into the field betweenthe coated surfaces, whereby the base fabrics are simultaneouslyflocked.

4. In the manufacture of flocked textile fabrics, the method ofsimultaneously flocking a plurality of adhesively coated base fabrics,including the steps of establishing a high potential electrostatic fieldof alternating polarity between opposing electrodes, positioning aplurality of adhesively coated base fabrics between the electrodes withtheir coated sides facing and introducing flock fibers into the fieldadjacent the coated surfaces, whereby the plurality of base fabrics issimultaneously flocked.

5. In the manufacture of flocked textile fabrics, the method ofsimultaneously flocking a plurality of adhesively coated base fabrics,in-

cluding the steps of establishing a high potential electrostatic fieldof regularly. alternating polarity between opposing electrodes,positioning a plurality of adhesively coated base fabrics'between theelectrodes so that the coated surface of each fabric faces the coatedsurface of another at spaced separation and introducing flock fibersinto the field between the coated surfaces, whereby the base fabrics aresimultaneously flocked.

6. In the manufacture of flocked textile fabrics, themethod ofsimultaneously flocking a plurality of adhesively coated base fabrics,including the steps of establishing a pulsating high potentialelectrostatic field of regularly alternating polarity between opposingelectrodes, positioning a plurality of adhesively coated base fabricsbetween'the electrodes so that the coated surface of each fabric facesthe coated surface of another at spaced separation and introducing flockfibers into the fleld between the coated surfaces, whereby the basefabrics are simulinto the field between the coated surfaces, whereby thebase fabrics are simultaneously flocked.

8. In the manufacture of flocked textile fabrics, the method ofsimultaneously flocking a plurality of adhesively coated base fabricswith flock fibers of poor electrostatic susceptibility, including thesteps of establishing a pulsating high potential electrostatic field ofregularly alternating polarity between opposing electrodes, positioninga plurality of adhesively coated base fabrics between the electrodes sothat the coated surface of each fabric faces the coated surface a ofanother fabric at spaced separation and introducing flock fibers of poorelectrostatic susceptibility into the field between the coated surfaces,whereby the base fabrics are simultaneous- 1y flocked.

9. In the manufacture of flocked textile fab-- rics, the method ofsimultaneously flocking a. plurality of adhesively coated base fabricswith flock fibers of good electrostatic susceptibility, including thesteps of establishing a high potential electrostatic field of regularlyalternating polarity between opposing electrodes, positioning aplurality of adhesively coated base fabrics between the electrodes sothat the coated surface of each fabric faces the coated surface ofanother at spaced separation and introducing flock fibers of goodelectrostatic susceptibility into the fleld between the coated surfaces,whereby the plurality of base fabrics is simultaneously flocked.

10. In the manufacture of flocked textile fabrics, the method ofsimultaneously flocking a pmrality of adhesively coated base fabricswith flock fibers of good electrostatic susceptibility, includpotentialelectrostatic field of alternating polaritybetwee-n opposing electrodes,positioning a plurality ofadhesively coated base fabrics between theelectrodes so that the coated surface of each fabric faces the coatedsurface of another at spaced separation and introducing flock fibers ofgood electrostatic susceptibility into the field between the coatedsurfaces, whereby the plurality of base fabrics is simultaneouslyflocked.

11. In the manufacture of flocked textile fabrics, the method ofcontinuously simultaneously flocking a plurality of adhesively coatedbase fabrics, including the steps of establishing a high potentialelectrostatic field of alternating polarity between opposing electrodes,continuously passing a plurality of adhesivelycoated basefabricssimultaneously through the electrostatic field and introducing flockfibers into the field adjacent the coated surfaces, whereby the basefabrics are simultaneously flocked.

12. In the manufacture of flocked textile fabrics, the method ofcontinuously imultaneously flocking a plurality of adhesively coatedfabrics, including the steps of establishing a high potentialelectrostatic field of regularly alternating polarity between opposingelectrodes, passing a plurality of adhesively coated base fabricssimultaneously through'the electrostatic field with the coated surfaceof each fabric facing the coated surface-of another at spaced separationand introducin'g fiock fibers into the field adjacent the coatedsurfaces, whereby the base fabrics are simultaneously flocked.

13. In the manufacture of flocked pile fabrics, the method ofsimultaneously flocking a plurality of adhesively coated base fabrics,including the steps of establishing a high alternating potentialelectrostatic field between opposing electrodes, positioning a pluralityof adhesively coated base fabrics between the opposing electrodes withthe coated sides of each pair of base fabrics facing each other andintroducingpile forming fiock fibers into the field and between thefabrics, whereby the base fabrics are simultaneously flocked.

14. An apparatus for the simultaneous flocking of a plurality of basefabrics, including opposing electrodes, means for establishing apulsating high alternating potential electrostatic field between theopposing electrodes, means for applying an adhesive coating to each of apluralityof base fabrics, spaced apart means for positioning theplurality of adhesively coated base fabrics between the electrode andmeans for introducing flock fibers into the field between the coatedsurfaces to fiock them.

15. An apparatus for the simultaneous flocking of a plurality of basefabrics, including opposing electrodes, means for establishingapulsatinghigh alternating potential electrostatic field between theopposite electrodes, means for applying an adhesive coating to one sideof each of a plurality of base fabrics, spaced apart means forpositioning the plurality of adhesively coated base fabrics between theelectrodes with the coated surface of each fabric facing the coatedsurface of another at spaced separation and means for introducing fiockfibers into the field'between the coated surfaces to fiock them.

16. An apparatus for the simultaneous flocking of a plurality of basefabrics, including opposing electrodes, means for establishing a highpotential electrostatic field of alternating polarity between theopposing electrodes, means for applying an adhesive coating to each of aplurality of base fabrics, spaced apart means for positioning theplurality of coated base fabrics between the electrodes and means forintroducing flock fibers into the field between the coated surfaces toflock them.

17. An apparatus for the continuous simultaneous flocking of a pluralityof base fabrics, including opposing electrodes, means for establishing ahigh potential electrostatic field of alternating polarity between theopposing electrodes, means for applying an adhesive coating to each of aplurality of base fabrics, spaced apart means for continuously movingthe coated base fabrics between the electrodes with coated surfacesopposed, means for introducing flock fibers into the field between thecoated surfaces to fiock them and means for drying and setting theadhesive.

GLEN SEFION HIERS.

